Spring unit



Feb. 12, 1963 F. G. HODGES, JR

SPRING UNIT Filed Sept. 4, 1959 INVENTOR.

BY m/XM/ United States PatentOl.

Patented Feb. l2, 1963 3,076,951 llltliNG UNIT Frederick G. Hodges, lr., 730 N. County Road, Palm Beach, Fla. Filed Sept. 4, 1959, Ser. No. 838,301 1 Elaine. (Si. 5-351) The present invention relates to a novel cushion or spring unit, and more particularly to a novel coil spring unit.

While it will be apparent that spring units constructed in accordance with the present invention may be adapted for various uses, they are particularly suitable for use as automobile or vehicle seat and bach rest cushions. Spring structures heretofore proposed for use in vehicle seats have frequently been unable to provide the degree of comfort desired. In addition, such heretofore proposed spring structures have, in many instances, been noisy in operation as a result of metallic squeaks and clicks which may occur during flexing of the unit. rfhus, in installations where the best available performance is desired, it has been the practice to utilize foam rubber cushions in place of spring structures even though the foam rubber is relatively expensive and has an undesirable characteristic of retaining heat.

it is an important object of the present invention to provide a novel spring or cushion unit which has substantially improved comfort or feel characteristics and which is more economical than foam rubber cushions now in general use.

A more specific object of the present invention is to provide a novel coil spring unit which is constructed so as to be noiseless in operation.

Still another obiect of the present invention is to provide a novel coil spring unit of the above described type having comfort characteristics comparing favorably with that of foam rubber while providing, in addition, a well ventilated cushion.

A further object of the present invention is to provide a novel coil spring unit of the above described type which is of simple construction and has a long useful life.

Gther objects and advantages of the present invention will become apparent from the following description'and the accompanying drawings wherein:

PEG. l is a plan view, partially broken away, showing a spring structure incorporating features of the present invention;

IFiG. 2 is an enlarged fragmentary plan view of a cushion unit incorporating features of the present invention having the covering fabric broken away to facilitate the disclosure of structural details;

HG. 3 is an enlarged fragmentary sectional view taken along line 3-3 in FIG. l;

FIG. 4 is a simplified sectional View showing one step in the manufacturing process of a spring unit incorporating features of the present invention;

FIG. 5 is a fragmentary sectional view taken along line 5 5 in PEG. 2 and showing the spring unit in an inverted position during a portion of the manufacturing process;

FiG. 6 is an enlarged fragmentary sectional view similar to FlG. 5 but showing a portion of the structure in an upright position and in greater detail; and

FG. 7 is a further enlarged fragmentary sectional view taken along line 7-7 in FlG. 2 and showing a feature of the structure in greater detail.

Referring now more specifically to the drawings wherein like parts are desingated by the same numerals throughout the various figures, a spring structure l0 is shown in FiGS. l and 3, which structure comprises an upper or outer coil spring unit i2 constructed in accordance with features of the present invention. The unit 12 is adapted to be mounted on various base or support structures. in the embodiment shown, the unit 12 is disposed on a foundation spring unit 14 comprising a plurality of relatively large and heavy coil springs 2.6.

It will be appreciated that the details of the structure of the foundation or supporting unit ld may be varied considerably. However, in the embodiment shown the springs i6 are secured to each other by clips ld and 2i) respectively connecting adjacent upper and lower end coils of adjacent springs. Upper and lower border wires 22 and 24 encircle the springs i6 of the unit ld and are connected to the opposite end coils of the uppermost springs by additional clips it and 2l). Preferably, the upper ends of the springs i6 are covered with a sheet Z of fabric or other suitable material which prevents direct contact between the spring unit l2 and the springs or metal parts of the support structure r-l. It is to be understood that the support structure i4 could utilize Zig- Zig or no-sag springs rather than coil springs and that in certain installations the support structure for the unit l2 may comprise suitable frame work or other means without the springs.

In accordance with the present invention, the unit l2 comprises a plurality of relatively small coil springs 2S formed from relatively light gauge spring wire. For example, the springs 2b are preferably formed from i6 or lli gauge wire. Each spring 28 comprises an upper or outer end coil Sli which has a generally planar configuration so that the springs 2S combine together and tend to provide the effect or feel of a continuous supporting surface. However, the maximum diameter' of each end coil 3*? is relatively small and may, for example, be on the order of one and one half inches whereby the springs may conform more closely to the body of a person resting on the unit.

Bottom or inner end coils 3?; of the springs 23 have a diameter similar to the maximum diameter of the end coils 3d and may or may not have inturned planar portions as desired. intermediate coils of the springs 23 progressively decrease in diameter from the opposite ends of the springs to the center coil so that the springs have a generally hour glass configuration. With this arrange- .rnent, the springs 2d provide an initially relatively soft feel and progressively iirmer support as they are cornpressed under the weight of a body. ln addition, with this arrangement adjacent coils of each spring tend to avoid each other when the springs are flexed or compressed so as to reduce any possibility of the occurrence of spring noises.

As shown in the drawings, the springs 23 are arranged in a predetermined pattern providing rows of springs eX- tending longitudinally and transversely of the unit. The springs 2d are disposed so that their end coils substantially abut end coils of immediately adjacent Springs and the end coils of adjacent springs are interconnected with each other at the areas of substantial abutment. More specifically, wire staples or clips 34 encircle the substanially abutting portions of adjacent upper end coils 3@ and identical wire clips or staples 36 are applied to the corresponding substantially abutting portions of the op posite end coils 32. Upper and lower margins of the pattern provided by the springs 2S are encircled by upper and lower border wires 3S and dil which are respectively secure-d to the adjacent upper and lower end coils at the outermost or peripherally arranged springs 23 by additional staples or ring-like wire clips 3d and 36.

In order to eliminate any possible spring noises in the unit l2, a thin, tough coating 42 of rubber or resilient rubber-like plastic material is applied to the springs 28, the clips 34 and 36 and the border wires 3d and di?. Preferably, this is accomplished by dipping the assembled springs into a bath 44 of liquid latex or rubber-like plastic as indicated in FIG. 4 after which the assembly maybe air cured or preferably passed through an oven, not shown, for heating and more rapid curing of the rubber or plastic material. The spring assembly is held in an inverted position for the dipping operation as indicated in FIGS. 4 and 5 so that as the spring assembly is raised from the bath and excess material drips from the assembly, a relatively rnore heavy layer of the coating material will remain on the lower portion of the spring assembly or, in other words, on what ultimately becomes the upper end coils 30, the clips 34 and the border Wire 38. Thus the portion of the spring assembly which receives the greatest wear and is rst engaged by the body of a person resting on the unit is provided with the relatively more heavy coating of material for improving the feel of the spring unit and reducing any possibility of spring noises for a longer period of time. As will be understood, the dipping and curing operation may be repeated several times to build up a coating of requisite thickness.

it is further to be noted that, as shown in FIG. 7, the rubber or rubber-like plastic material not only encircles the staples or clips but also substantially completely lills the space defined by the clips and surrounding the abutting portions of the spring end coils so that a still heavier mass of the coating material is provided at the areas of maximum wear, or in other words, at the points where the springs are connected to each other or to the border wires. ln making the spring unit 12 preferably the coil springs are first formed, and then tempered, and then clipped together, and the coating material then applied.

The spring unit 12 may be secured to the support structure 14 by any suitable means such as additional clips or staples 46 extending around the border wires 22 and 40. The rubber coating on the inner end coils 32 not only acts as a silencer but also helps to reduce wear and tear o-n the fabric sheet 26 covering the support structures. In order to complete the spring structure, an insulator 48 is applied over the upper end coils 30 of the unit 12, and the entire assembly is enclosed with a suitable fabric or cover 50. A padding 52 of felt or other suitable material may be provided between the cover 50 and the insulator.

While the preferred embodiment of the present inven- Vtion has been shown and described herein, it is obvious that many structural details may be changed Without departing from the spirit and scope of the appended claim.

The invention is claimed as follows:

A spring unit comprising a plurality of wire Coil springs disposed in side-by-side relationship in a predetermined spring pattern with the axes of said springs being parallel and with the end coils of each spring abutting the end coils of adjacent springs throughout the spring pattern, upper and lower border wires extending respectively around the upper and lower margins of the spring pattern and abutting the upper and lower end coils of the outermost springs in the spring pattern, ring-like clip elements 'of wire having a substantially uniform and relatively small cross section with one each of said clip elements reSpectively securing abutting portions of the upper end coils and abutting portions of the lower end coils and abutting portions of the upper and lower end coils of the outermost springs respectively to the upper and lower border wires with minimum surface contact between the respective clip elements and end coils and border wires, each clip com` prising a wire loop having terminal legs with the free ends thereof in crossed relationship and disposed at a substantial angle with respect to the plane of the end coils, said legs extending toward the central plane of the spring unit, and a coating of tough resilient rubber-like material covering substantially all portions of the springs and clip elements and border wires and with the minimum surface contact between the respective clip elements and end coils and border wires permitting the space within each clip element to be substantially completely filled with the rubber-like material to cover the end coils and border wires within the respective clip elements, said coating completely covering said legs and the free ends thereof.

References Cited in the file of this patent UNITED STATES PATENTS 1,275,318 Stevens Aug. 13, 1918 1,359,120 Smith et al. Nov. 16, 1920 1,387,743 Van Hove Aug. 16, 1921 1,804,722 Van Hove May 12, 1931 2,058,165 McCoy Oct. 20, 1936 2,247,543 Bernstein July 1, 1941 2,803,293 Rowland Aug. 20, 1957 2,954,076 Crane et al. Sept. 27, 1960 FOREIGN PATENTS 824,037 France Nov. 3, 1937 

